Caledyne Celebrates Second Size Torus Safety Valve Test Success

Caledyne, a leading energy industry engineering services and products specialist, has announced the successful qualification of a second size of its Torus insert safety valve, adding a 4.1/2" version to the existing 2.7/8".

The Torus Safety Valve has opened up many new opportunities for enhancing production from mature fields. Improving on a basic flapper type safety valve design, the torus safety valve allows for a central conduit to pass through the core where the conduit may be hydraulic (mini-coil or capillary string), electrical or fibre-optic. This allows for the installation of artificial lift or downhole monitoring in existing wells without the requirement of a full workover resulting in huge cost savings.

This project was facilitated into a joint industry collaborative project by ITF (Industry Technology Facilitator), allowing the 4.1/2" torus valve to achieve API 14A accreditation at an independent facility in the USA. Testing for API 14A qualification involves analysing gas and fluid leak rates for the test subject at both ambient and elevated temperatures.

Typical applications of the valve include liquid loading, chemical stimulation to prevent scale build-up, injection of corrosion inhibitors, downhole monitoring and insert gas lift. The 4.1/2" valve has completed further testing allowing a rotational umbilical to be installed through the valve. This has now opened up an entirely new market as Progressive Cavity Pumps (PCP) can be installed in offshore and safety valve applications. Simultaneously, Caledyne has developed a suite of surface and downhole solution complementing the Torus valve installation providing a complete solution from top to bottom.

The technology has a number key benefits over alternative solutions including:

  • An optimized design to reduce part count and complexity.
  • A minimal number of pressure seals reduces potential leak paths. There are three dynamic seals and three static seals in the entire assembly.
  • Its modular design allows the same basic valve to be configured to accept the particular penetrator for the application.
  • The system is installed as per industry standard wireline insert safety valves and can be easily fitted on coil tubing for hanger applications, such as insert electric submersible pumps.

The success of the Torus Safety Valve has lead to Caledyne launching a new range of downhole valves, which includes the Caledyne Fluid Loss Valve (FLV), Mechanical Isolation Valve (MIV) and Completion Barrier Valve (CBV). With a range of applications ranging from formation protection for the FLV, to formation isolation for the MIV and CBV, the technology signals an exciting branch of innovation from the company.

David Martin, Technology director of Caledyne and one of the inventors of the Torus Safety Valve said, "We see the Torus safety system as an enabling technology. The Torus valve allows various operations to be carried out, which in the past were unachievable, because the safety case could not be answered.

"We foresee a drive towards techniques such as installation of progressing cavity pumps offshore, which can deliver increased recovery of oil and gas assets at lower cost than at present. Utilising the Torus valve does not only provide a technical solution to umbilical problems, the unique concentric design also minimizes flow restrictions resulting in a much greater flow area then traditional flapper type bypass valves."

Callum Munro, well operations engineer for BP, added, "BP as co-sponsor of the joint industry project participated in the development of the Torus Valve. This was seen as an exciting and progressive game-changer in the area of depleted gas wells, which suffer from liquid loading issues. The delivery of both 2 7/8" & 4 1/2" versions, now provide the market with increased options to extract additional reserves in mature gas provinces."

Caledyne managing director, Roland Van Dort, will be discussing Caledyne's new valve range at the Offshore Technology Conference on Houston on May 4-7 on stand 2363.